WORKSHOP CALCULATION

Introduction to Units ( Pressure)

PRESSURE CONVERSION Bar. 1 Kg / cm = 14 . 223 psi ( Lb / In ) 1 Kg / cm = 0 . 9807 1 PSI = 0.07031 Kg / cm

Introduction to Units (Length)

1m = 100 cm 1cm = 10 mm 1m = 1000 mm 1in. = 25.4 mm
3

Introduction to Units ( Temperature)

Temperature unit = Degree Celsius or Degree Fahrenheit

C = 5/9(f-32)
If Temp. Is 100f, Then So, C=37.7 C=5/9( 100-32)

If Preheat Temp. Is 150c, Then F=302

PYTHAGORAS PRINCIPLE APPLICATION

A

Pythagoras Principle : In Any Right Angled Triangle a Sum of Adjacent Side Square Is Always Equal to It Hypotenuse Square.
B C

LET US SAY

ABC is right angle triangle .

AB and BC = Adjacent sides and AC = Hypotenuse. So based on pythagoras theory ,

AB + BC = AC
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PYTHAGORAS PRINCIPLE APPLICATION

Example :
A 3 5

Proof of theory in triangle ABC AB = 3 , BC = 4 and AC = 5 SO AC = AB + BC = 3 + 4 = 25 By taking AC = 5 so AC = 25 It means that LHS = RHS

TRIGONOMETRIC FUNCTIONS
A

Trigonometric functions are used to solve the problems of different types of triangle.
B C

We will see some simple formulas to solve right angle triangle which we are using in day to day work.

Let us consider ABC is a right angled triangle, Angle ACB = , AB & BC are sides of triangle. So for this triangle.
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TRIGONOMETRY
A

Hypoteneous Opposite Side

SIN

= Opposite Side = AB AC Hypoteneous = Opposite Side = AB BC Adjacent Side

TAN
C

Adjacent Side

COS =

Adjacent Side = BC AC Hypoteneous

TRIGONOMETRIC FUNCTIONS
Example : For triangle ABC find out value of and . A
25 mm We Will Find Value Of By Tangent Formula So , Tan = Opposite Side / Adjacent Side = AB / BC = 25/25 =1 Tan = 1 = Inv. Tan(1) = 45 Now, We Will Find AC By Using Sine Formula Sin = Opposite Side /Hypotenuse = AB / AC Ac = AB / Sin = 25 / Sin45 =25 / 0.7071 = 35.3556mm

25 mm

TRIGONOMETRIC FUNCTIONS
Example: We Will Find Value Of By Cosine Formula A
25 mm

B
25 mm

Cos = Adjacent Side / Hypotenuse = AB / AC = 25 / 35.3556 = 0.7071 = Inv Cos (0.7071) = 45

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TRIGONOMETRY
Example:
A

FIND OUT ANGLE OF A TRIANGLE

SIN

= OPPOSITE SIDE =
HYPOTENEOUS = 30 50 = 0.60

AB AC

OPPOSITE SIDE 30

HYPOTENEOUS 50

B ADJACENT SIDE C

= InvSINE VALUE OF 0.60 = 36 - 52

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AREA
Definition : A surface covered by specific Shape is called area of that shape. i.e. area of square,circle etc.

1. Square :

Area Of Square = L X L = L
L Where L = Length Of Side L

So If L Then Area

= 5cm = 5 X 5 = 25cm
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FIND OUT SIDE OF A TRIANGLE Example:

A

TAN = OPPOSITE SIDE = AB ADJACENT SIDE BC

HYPOTENEOUS

OPPOSITE SIDE 20

TAN 36 = BC =

20 BC 20 TAN VALUE OF 36 20 0.727 27. 51 mm

36 B

?
ADJACENT SIDE

BC = BC =

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AREA
2. Rectangle:
Area Of Rectangle = L X B Where, L B If L= 10 mm, And B Then, Area = Length = Width = 6 mm = 10 X 6 = 60mm
B L

3. Circle :

Area Of Circle =

/ 4 x D

Where D= Diameter Of The Circle

Area Of Half Circle = /8 x D

D

Same way we can find out area of quarter of circle

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AREA
4 . Circle : Hollow Circle =

x (D - d)
4

WHERE D = Diameter of Greater Circle d = Diameter of Smaller Circle

Sector Of Circle=

xDx
4 x 360

D
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AREA
4. Triangle : Area Of Triangle = B x H
Where B H = Base Of Triangle = Height Of Triangle B H

5. Cylinder : Surface area of Cylinder =xDxH

Where H D = Height Of Cylinder = Diameter Of Cylinder
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VOLUME
Defination : A space covered by any object is called volume of that object.

1. Square block : In square block;

width and height are equal, so

length,

L L L

Volume Of Sq. Block = L X L X L = L 2. Rectangular Block : Volume= L X B X H

Where L = Length B = Width H = Height

H L

B
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VOLUME

3.Prism or Triangle Block : Volume of Triangular Block = Cross Section Area of Triangle x Length ( Area of Right Angle Triangle = B H ) Volume = B H X L Where B = Base of R.A.Triangle H = Height of R.A.Triangle L = Length of Prism
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VOLUME
4. Cylinder : Volume of Cylinder = Cross Section Area x Length of Cylinder Volume= D X H Where : D = Diameter Of Cylinder H = Length Of Cylinder
D
H

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CG CALCULATION
CG
m TAN LINE

DIA

CENTRE OF GRAVITY OF DENDS ( CG ) (1) (2) (3) HEMISPHERICAL 2:1 ELLIPSOIDALS TORI - SPHERICAL ( m ) = 0.2878 r DIA ( m ) = 0.1439 r DIA ( m ) = 0.1000 r DIA

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WEIGHT CALCULATION
Examples : Weight calculation of different items: Rectangular plate Circular plate Circular plate with cutout Circular sector Shell coursce

Specific gravity for (i) C.S.= 7.86 g/cm3 (ii) S.S.=8.00 g/cm3
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WEIGHT CALCULATION
Examples : 1. Rectangular plate :
Weight of This Plate 3.5 CM 200 CM = Volume X Sp.Gravity = L X B X H X 7.86gm / CC Here L = 200cm, B = Width = 100cm And H = Thk = 3.5 cm So Volume = 200 X 100 X 3.5 cm = 70000 cm Now Weight Of Plate = Volume X Sp .Gravity = 70000 X 7.86 gm/cc = 550200 gms = 550.2 kgs
10 0
22

CM

WEIGHT CALCULATION
Examples :
2. CIRCULAR PLATE : Weight= V X Sp. Gravity Volume V= Cross Section Area X Thk = D X 4cm = x 300 X 4cm = 282743.33 cm So W = V X sp.Gravity = 282743.33 X 7.86 gms/cc = 2222362.5738 gms = 2222.362 kgs
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300 cm

Thk = 4cm

WEIGHT CALCULATION
Examples : Circular sector : Weight of Circular Plate Sector :
W = Volume X Sp.Gravty. Now Volume = Cross Sec.Area X Thk = X ( R1 - R2) X X 2 cm 360 = X (400 - 350) X 120 X 2 360 = 78539.81 cm Now Weight = V X Sp .Gravity = 78539.81 X 7.86 gms/cc = 617322.95 gms = 617.323 kgs R1 R2 = 120

R1 = 400 cm R2 = 350 cm THK = 2cm = 120

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WEIGHT CALCULATION
Examples :
300 c m

Shell : W = V X Sp.Gravity V= X ( OD - ID ) X Length 4 00 c m Here OD = 400 + 10 = 410cm ID = 400cm Length = 300cm 5cm So V = X ( 410 - 400 ) X 300cm = 1908517.54cm Now Weight W = V X Sp. Gravity = 1908517.54 X 7.86 = 15000947gms = 15000.947kgs = @ 15 Ton

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WEP CALCULATION
SINGLE 'V'
A B
=600

In

given

figure,

to

find

out

Distance, we will use 98 Trigonometric formula. Tan / 2 = AB / BC Here AB = ?, BC = 98, / 2 = 30 Tan 30 = AB / 98 AB = Tan 30 X 98 = 56.54 mm
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100

C 3

WEP CALCULATION
Double V
= 450 40 2 = 18 600 3

For double v also we can calculate distance by

THK =60

same trigonometric formula. two types: 1. Equal v 2. 2/3 rd &1/3 rd.

Double v are

of

T joint In t joint also by tan formula we can find WEP dimensions:

40THK

=
C

=
= 500
A
B

AC = 20 , = 500 , AB = ? Tan = AB / AC AB = 20 x Tan 500 AB = 23.83

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WEP CALCULATION
COMPOUND 'V'
P= 10 56 q= 45 12
R.F.= R.G.= 3 2

THK=70

In such kind of compound V, we always do machining to take care of all calculation. As shown by dotted line, we can calculate WEP dimensions by sine or tangent formula.

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WELD METAL WEIGHT CALCULATION

Weld metal weight = Cross section area of particular WEP x length / circumference of seam x density

Basically weld metal weight calculation involves Calculation of volume, trigonometry and Weight calculation.
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30

WELD METAL WEIGHT CALCULATION

Basic fundamentals of weld metal weight Calculation 1.Single v for long seam and circseam Long seam weld weight = Cross section area x length of seam x density Circ. seam weld weight `= Cross section area x mean circ. of seam x density

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WELD METAL WEIGHT CALCULATION

3
1

=60
3 4 2

Now A1 = 2/3 x H x Bead Width A1 = 2/3 x 0.3 x 6 cm = 1.2 cm 50 Now A2 =A3 A2 = 1/2 x B x h = 0.5 x B x 4.7 cm Here B= 47 Tan30 =2.713cm A2 = 0.5 x 2.713 x 4.7 Cm = 6.38 Cm A3 = 6.38 Cm A4 =0.2 * 4.7 cm
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3 2 1.Crossection Area Of Joint A = A1 + A2 + A3 + A4

Now A = 1.2 + 6.38 + 6.38 + 0.94 cm A = 14.9cm

WELD METAL WEIGHT CALCULATION

For long seam weld weight = Cross section area x Length of seam x density = 14.9cm x 100cm x 7.86gm/cm = 11711.4gms = 11.712kgs for 1 mtr long seam For circ. seam = Cross section area x Mean circ. x Density For Circ. seam having OD = 4000 mm and Thk. = 50 mm Weld Weight = 14.9cm X 1240.9 cm X 7.86 gms/cc = 145326gms = 145.326kgs.
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TAPER CALCULATIONS
Whenever a Butt joint is to be made between two plates of different thickness, a taper is generally provided on thicker plate to avoid mainly stress concentration. 1:3 Taper 40 x 60

Thickness Difference = 60 - 40 = 20mm. X = 20 x 3 = 60mm. Instead of 1:3 taper, if 1: 5 Taper is required; X = 20 x 5 = 100 mm.

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MODULE : WORKSHOP CALCULATION UNIT : 3

Measure tape error correction and circumference calculation = with demonstration (1 hour) Orientation marking ( 0.5 hour ) Offset and kink, web and flange tilt, flange unbalance calculation (1 hour) Arc length and chord length calculation for web layout= with demonstration ( 0.5 hour ) Practice examples = 10 nos. (1 hour)
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USE OF CALIBRATION TAPE

How to refer calibration report? Consider total error for calculation. Standard error & relative error are for calibration purpose only. How to use calibration report? Marking - Add the error. (Mad) Measuring - Subtract the error (Mes) During calculation, always put error value in brackets.
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USE OF CALIBRATION TAPE.

Example: Cut 1meter long bulbar Tape-01 Total error at 1m (+1) 1000mm+(+1)mm Marking at 1001mm Length found 1001mm 1001-(+1)mm 1000mm actual length Tape 02 Total error at 1m (-1) 1000mm+(-1)mm Marking at 999mm Length found 999mm 999-(-1)mm 1000mm actual length
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Marking of 1 m (add the error)

measure the length(subtract the error)

Tape 01 (+1 mm error)

Bulb bar

Marking 1000+(+1) mm Measuring 1001- (+1) mm error Actual 1000 mm

38

Tape 02 (-1 mm error)

Bulb bar

Marking 1000+(-1) mm Measuring 999 - (-1) mm error Actual 1000 mm

39

CIRCUMFERENCE CALCULATION
Circumference = Pie x Diameter of job If I/D is known and O/S circ. Is required then, Circumference = Pie x ( I/D + 2 x thick ) Here Pie value is very important. Which is the correct value of pie? 22/7 3.14 3.1415926 (Direct from calculator/ computer)

40

CIRCUMFERENCE CALCULATION
Example 1 : O/S Dia of the job is 10000mm, calculate O/S circumference. 1) 10000mm x 22/7 2) 10000mm x 3.14 = 31428.571mm = 31400.00mm

3) 10000mm x 3.1415926 = 31415.926mm

41

CIRCUMFERENCE CALCULATION
Example 2 : Internal T-frame o/d - 9998mm Shell thickness - 34mm ,Root gap - 0.5mm Calculate shell o/s circumference. Shell o/d = T - fr o/d 9998mm + root gap (0.5mm x 2) + thickness (34 x 2mm) = 10067mm Circumference = Pie x 10067mm If pie = 3.1415926 If Pie = 22/7 If Pie = 3.14 then circ. = 31626.4mm then circ. = 31639.14mm then circ. = 31610.38mm
42

OFFSET CALCULATION
Thickness difference measured from I/s or o/s on joining edges is called offset. offset

Tolerance as per P-1402 0.1T but <= 2mm for web & <= 3mm for flange Say T = 34 mm than, Offset = 0.1 x 34mm = 3.4mm

But max. 3mm allowed as mentioned above. If by mistake 0.1% T considered than, 0.1 x 34/100 = 0.034 mm offset which is wrong.
43

OFFSET CALCULATION
How to measure offset & kink ? Here A = D Offset = B - C Kink = ( A - B or C - D ) which ever is max. Kink is nothing but peak-in/ peak-out C B A
44

OFFSET CALCULATION
How to measure offset& kink in case of thickness difference? Here A = D Offset = B - C Kink = ( A - C or B - D ) which ever is max. Kink is nothing but peak-in/ peak-out A
45

D C B

ORIENTATION MARKING
Start orientation in following steps. Measure circumference. Check long seam orientation from drawing. Find out arc length for long seam from 0 degree. Arc length = (circ./360 ) x Orientation. Always take all digits of orientation given in drawing.

46

ORIENTATION MARKING
Example : O/S circ. L/S orientation = 25300mm

= 75.162 degree

Find out arc length for 75.162 Arc length for L/S = ( 25300/360 ) x 75.1 = 5277.86mm

= ( 25300/360 ) x 75.16 = 5282.07mm = ( 25300/360 ) x 75.162 = 5282.218mm

47

TOLERANCES
Always read the drawing carefully to interpret tolerance correctly. (1) Pre-tilt of web : For 101 mm to 150 mm frame height -0.025H but 3mm Example: H = 120mm then, pre tilt = 0.025 x 120 = 3mm

48

TOLERANCES
How to check Pre tilt of web :[ X-Y ] = pre tilt

49

TOLERANCES
(2) Flange pre tilt : <= 3mm [ X-Y ] = Pre tilt

50

TOLERANCES
(4) Out of circularity (OOC) : 0.2 % R ( R-theoretical radius of PRB ) Example : R = 4000mm OOC = 0.2 x 4000/100 = 8mm (5) Flange position w.r.t web : (Flange unbalance) :+/- 1mm [ X - Y ] = 2mm X

Y
51

Example:
L h C r a

L a c q r h

= ARC LENGTH = AREA OF SEGMENT = CHORD LENGTH = ANGLE = RADIUS = HEIGHT BETWEEN CHORD TO ARC

q
(1) c= 2 h (2r -h)

(5) L= (6) q =

0.0174533 57. 29578 r

rr r r

( 2 ) a = 1/2 [ rL - c ( r - h ) ] (3) h = r - 1/2 4 r 2 - C2

( 7 ) h = r [ 1 - COS ( q / 2 ) ] ( 8 ) C = 2r ( Sin q / 2) ( 9 ) X = PCD ( Sin 180/ N)

(4)r = c2+4h2 8h

X= Straight Distance between 2 holes & 52 N= No. of Holes

CHORD LENGTH
A 60 C R B

Example : Web segment size - 600 Inside radius R - 4000mm Sine 30 = CB/4000mm 1/2 chord length CB = 0.5 x 4000mm = 2000mm Full chord length = 4000mm

53

PYTHAGORAS PRINCIPLE APPLICATION

Trimming height calculation in hemispherical Dend For matching OD / ID of Dend to shell OD / ID we have to do actual Marking on Dend for trimming height We can find out trimming height by Pythagoras theory As shown in figure, we can have E Following dimension before Marking trimming A B AB = Radius of Dend. Based on act Circumference at that end T.L AC = CD = Dend I/S Radius as per C DRG. from T.L BC = Straight face or height from T.L TO Dend. edge ED = Dend radius calculated from its matching parts Circumference BE = Trimming height req to maintain for req circumference of 54 Matching part circumference

PYTHAGORAS PRINCIPLE APPLICATION

Example : AB = 1500mm AC = CD = 1510mm BC = 173.5mm ED = 1495mm BE = ?

E A B T.L C

Based on Pythagoras theory In triangle CED CE + ED = CD CE = CD - ED = 1510 - 1495 CE = 212.3mm Now CE = CB + BE BE = CE - CB = 212.3 - 173.5 = 38.8mm

55

TRIGONOMETRIC FUNCTIONS
Tank rotator rollers dist. Calculation As shown in figure we can find out Two things : 1. Angle between two rollers 2. Dist. Between two roller for specific diameter of shell . We will check it one by one. For safe working, angle Should be between 45- 60
C D B A

56

TRIGONOMETRIC FUNCTIONS
Tank rotator rollers dist calculation
1. Angle between 2 roller: As shown in figure BC = Half of the dist between two rollers AD = Shell o/s radius DC = Roller radius So we can get above dimensions from DRG and Actual dist from tank rotator Now as per sine formula Sin /2 = BC/ AC AC = AD + DC ( Shell OD + Roller DIA ) Sin /2 = BC / (AD +DC) Now If We Take BC = 1500 mm, AD = 2000mm AND DC = 400 mm Then Sin /2 = 1500 / (2000 + 400 ) = 1500 / 2400 = 0.625 Sin /2 = 0.625 /2 = INV Sin 0.625 = 38.68 = 2 X 38.68 = 77.36
57

D C B

TRIGONOMETRIC FUNCTIONS
Tank rotator rollers dist calculation :
2.Roller dist. By deciding angle Between two roller
If We Keep Roller Angle = 75 AD = Shell O/s Radius = 3000mm DC = Roller Radius = 400mm CE = Dist. Between Two Roller = CB + BE = 2 X CB (CB = BE) Now By Sine Law Sin /2 = BC/AC BC = Sin /2 X AC BC = Sin37.5 X 3400 (= 75 /2 = 37.5, AC = AD + DC = 3000 + 400) BC = 0.6087 X 3400 = 2069.78 mm Dist.Between Roller CE = 2 X BC = 2 X 2069.78 = 4139.56mm
58

PCD & HOLE MARKING CALCULATIONS

For Example, consider a flange 14-1500# with P.C.D.=600 mm & No. of Holes N = 12. Mark P.C.D. = 600 mm. Angular distance y = 360 / N = 360/12 = 30 degrees. Chord length between holes = 2 x PCD x Sin ( y/2 ) 2 = 2 x 600 x Sin (30/2) N Holes = 2 x 600 x 0.2588 = 155.28 mm. 2
59

Y/2

P.C.D.

SLING ANGLE CALCULATION.

Hook

50 00

4000

60

SLING ANGLE CALCULATION.

50

00

2000

61

CALCULATIONS

Sin = x/y x = 2000 = 23.5 0 2 = 23.5 X 2 = 470 & y = 5000

62

M/CING ALLOWANCES
Add 3 mm (min.) on all dimensions to provide for m/cing allowances. Example of O/Lay on Gasket face of Flange:
2106 dia.(min.) 5 8 (min.)

1894 dia.(max.) 1900 dia.

63

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